Process and device for controlled deformation of spine fins while shaping of coils

ABSTRACT

A method and system device for controlled deformation of spine fin coil. A spine fin tubing is placed and guided through a conduit constructed with comb-like teeth so that the spine fins are deformed by the comb-like teeth in a controlled manner. The controlled deformation can be performed either before or during winding with a winder and/or after a coil is made.

CROSS-REFERENCE

This is a continuation-in-part application to the US application No.,filed on, from which priority is claimed, and entirety of which ishereby incorporated by reference, and also claims the benefit of U.S.Provisional Application No. 61/108,070 filed on Oct. 24, 2008, theentirety of which is hereby incorporated by reference.

DESCRIPTION OF RELATED ART

The present invention relates broadly to the field of heat exchangers,and more specifically to a method and device for continuously formingspine fin coil type heat exchangers with controlled deformation.

Note that the points discussed below may reflect the hindsight gainedfrom the disclosed inventions, and are not necessarily admitted to beprior art.

Spine fins have been attached to heat exchange tubes of a continuousheat exchanger to increase heat exchange efficiency. The spine fins andthe base tubing are generally fabricated of aluminum by wrapping thealuminum tubing with aluminum spine fins that are fixed with “newmetallic like” adhesive materials. For thermal conduction of heat, airmust travel through the fins, and through the glue through the tubing tothe refrigerant inside the tubing. Spine fins generally increase theheat exchange surface area, when the air moves over the fins. The “twopart” type” adhesive is to increase the “kelvin” unit of measure.

In the manufacturer of spine fin heat exchanger tubes it is common toform bends in the tubes at selected locations along its length by applya force to the tube through the spine fin material to produce the bends.The most common types are various forms of coils with spine fined heatexchange tubes packing together in circles.

As the coil is made, spine fin wrapped tubing is hooked to a coilwinding mandrel, and the coil winder horizontally turns around andaround, bending the tubing into layers. Each wrap is layered beside theother until the correct number of wraps is made for the correct heightof the coils and the coil is then processed on through the assemblyline.

During the application of such bending force the spine fins at the bendmay be pressed together or be severely damaged and mutilated as the bendis formed. The damaged spine fins would block air passage and reduceheat exchange. At the corners of the shaped spin fin coils, the currentcoil winder machines also cause the fins to bend to a degree that arenot optimal efficient surface area utilization of the fins themselves.This excessive bending does not allow for optimal cooling with the airconditioning unit.

Therefore, it is desirable to provide apparatus and method which willcontrol the pattern deformity and does hot crush the spine fins afterforming bends in the shaper in the spine fin tubing but will reduce thedamage and improve the process. The fins in short radius bends can beremoved to some degree. This will reduce pattern deformation.

SUMMARY

The present application discloses a novel virtualized software platformat the application (i.e. client in the context of client/server model)software level to function as part of a novel distributed computerserver system for distributed computing and services via the Internetand network system.

A method and devices including winders, reels, shapers and/or otherprocesses are designed to provide controlled deformation of spine finswhen forming a spine fin tube into a coil. The spine fin heat tube coilsare used as a heat exchanger for a residential air conditioning unitand/or any refrigeration unit. Any and all useable spine fin tubing canbe processed on an adjustable shaper reel or a coil winder with a shaperhaving a guiding rail with comb like teeth or bridge or pin teeth forcontrolling the degree of deformation of the spine fins.

In one embodiment, the shaper reel is capable of expanding and/orretracting to different sizes to accommodate any size spine fin coil forbending.

In one embodiment, a double lines of guiding teeth are configured on awinder conduit to fit and guide the deformation of the spine fins fromboth the inside and the outside of a spine finned coil.

The guiding teeth may be formed by bridges, pins, reversed brushes, a Vshaped tool or an array of other deformation tools that may be used toachieve the desired deformation or the placement of the fins as they areredirected.

The foregoing has outlined, rather broadly, the preferred feature of thepresent invention so that those skilled in the art may better understandthe detailed description of the invention that follows. Additionalfeatures of the invention will be described hereinafter that form thesubject of the claims of the invention. Those skilled in the art shouldappreciate that they can readily use the disclosed conception andspecific embodiment as a basis for designing or modifying otherstructures for carrying out the same purposes of the present inventionand that such other structures do not depart from the spirit and scopeof the invention in its broadest form.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosed application will be described with reference to theaccompanying drawings, which show important sample embodiments of theinvention and which are incorporated in the specification hereof byreference, wherein:

FIG. 1A is a front view of an example Spine Fin machine for attachingspine fins to a tubing.

FIG. 1B shows a side view of an example spine fin tubing.

Coil,

FIG. 1C shows a perspective view of an example spine fin tubing coil.Panel nets can be installed to protect the fins and to make cleaningeasier.

FIG. 2A shows an example damaged spine fin tubing.

FIG. 2B shows an un-controlled deformation of spine fin at the bendingcorner of spine fin tubing coil. In these point the fins, can be removedand or thinned out

FIG. 3 is a top view of an adjustable shaper reel or winder capable ofexpanding and/or retracting to different sizes to accommodate any sizespine fin coil in bending in accordance to this application.

FIG. 4A is a top view of an example of an adjustable shaper reel orwinder having a guiding conduit with comb like teeth for controlledspine fin deformation during bending.

FIG. 4B is a top view of another example of an adjustable shaper reel orwinder having a guiding conduit with comb like teeth for controlledspine fin deformation during bending in accordance with thisapplication.

FIG. 5A schematically shows an example crushing device configurationduring manufacturing process of spine fin tubing in reducing spine findamages in accordance with this application.

FIG. 5B schematically shows another example crushing deviceconfiguration during manufacturing process of spine fin tubing inreducing spine fin damages in accordance with this application.

DETAILED DESCRIPTION OF SAMPLE EMBODIMENTS

The numerous innovative teachings of the present application will bedescribed with particular reference to presently preferred embodiments(by way of example, and not of limitation). The present applicationdescribes several embodiments, and none of the statements below shouldbe taken as limiting the claims generally.

For simplicity and clarity of illustration, the drawing figuresillustrate the general manner of construction, and description anddetails of well-known features and techniques may be omitted to avoidunnecessarily obscuring the invention. Additionally, elements in thedrawing figures are not necessarily drawn to scale, some areas orelements may be expanded to help improve understanding of embodiments ofthe invention.

The terms “first,” “second,” “third,” “fourth,” and the like in thedescription and the claims, if any, may be used for distinguishingbetween similar elements and not necessarily for describing a particularsequential or chronological order. It is to be understood that the termsso used are interchangeable. Furthermore, the terms “comprise,”“include,” “have,” and any variations thereof, are intended to covernon-exclusive inclusions, such that a process, method, article,apparatus, or composition that comprises a list of elements is notnecessarily limited to those elements, but may include other elementsnot expressly listed or inherent to such process, method, article,apparatus, or composition.

Currently, spine fins coils are manufactured in various steps. First, aspine fin machining wrapper is used to put the spine fins on to theoutside surface of a tube. Then, if the coil is to have a square shape,the spine fin tube is transferred to a coil winder which makes the bendsto form the shape. It is during this process when the coil is beingshaped in the shaper that the spine fins on the inside corners of thecoil being bent that the spine fins that are deformed and flattened.

In reference to FIGS. 1A and 1B, an example continuous spine fin heatexchanger 10 is of the type having a continuous spine fin material 12helically wound on a base tube member 14. A suitable base tube member 14is fed vertically upward through the crushing machine 16 in FIG. 1A byfeeding means 18 through the machine 16. A rotating support table 20 isarranged for rotation about a vertical axis. The table 20 carries a coilof sheet stock 21 which is fabricated into the spine fin material 12 aswell as the fin wrapping and forming assembly 22. In operation the tubebase member 12 is fed through an axial passage in the rotating supporttable 20 and past the fin wrapping and forming assembly 22. The formingassembly includes means for bending the strip stock to form a baseflange 24 and for lancing the strip to form fin sections 25. Thewrapping assembly includes means for helically winding the spine finmaterial 12 onto the base tube member 14 as it advances through themachine 16 under tension so that the base flange 24 is in intimate heattransfer contact with outer tube wall. As shown in FIG. 1C, thecontinuous spine fin heat exchanger 10 may be further wound together bya coil winder to form a coil. There is also a Panel Net. The net iswrapped around the coil to keep debris from being pulled into the coilfins and thus reducing the efficiency of the air coil itself in regardto thermal transfer. The net can be changed and or cleaned periodicallyand used for routine maintenance. It is noted that panel nets can beinstalled in the manufacturing process or at the time of the first coilcleaning.

When forming the coil from a round shape to square or similar shape, theoutside and inside surfaces of the bend portion of the coil are pressedor bent to the desired shape. In this process the fins are mashed downat the four inside corners because the fins are delicate and are easilycrushed. During this processing, the spine fin can be either damaged(FIG. 2A) or be bent together. These crushed spine fins can cause anunwanted air flow restriction that, over time, can lead to a buildup ofdirt and debris which can cause an undesired air flow restriction.

The fins are molded very delicate. When spine fin tubing's are formed ortubing coils are formed, a mechanical apparatus is provided forcontrolled deformation. There are several way and points in themanufacturing process that this controlled deformations can take placeand this process can be at the discretion of the customer.

Referring to FIG. 3, there is shown an adjustable reel 40 which can beconfigured to receive a spine fin coil that has any shape from round tosquare and, when used as a shaper, can form coils having various shapes.With the shaper shown, when a square spine fin coil is formed, the spinefins on the inside corners of the coil will not be smashed, butcontrolled. The adjustable reel 40 has a center hub 42 which is coupledto and is controllably rotate by a variable speed drive motor, notshown.

Projecting outward from the center hub are eight arms 44, each of whichis coupled to a pneumatically operated cylinder having a piston 46 whichis adapted to selectively increase or decrease the lengths of the arms44. In place of the pneumatically operated cylinder having a piston, anyother mechanism such as an electrical motor coupled to operate a scissorlift mechanism or a screw mechanism can be used. Located at the outerend of each arm is a plate 48 which receives and supports the spine fintube 49. The plates that are located at inside corners of the coil arecurved to allow the spine fin tube to bend without crushing the spinefins on the inside of the bend. The surface can be spring loaded and/orhave plates that pivot, slide up and down and/or move with the bendingmotion and are fully or partially loaded. Depending on the type andconfigurations of the plates and the lengths of the various arms, coilshaving a circular shape and coils having part circular and flat sidescan be made.

The shaper shown can make a coil having three straight sides, one curvedside and two rounded corners. The shape of coils that can be made withthe adjustable shaper reel 40 is limited only by the number of arms thatthe shaper has and the type of plates that are on the ends of the arms.With the correct number of adjustable arms and cooperating plates, coilshaving eight or more sides can be made. In the areas of the coil wherethe spine fin coil is straight, the plates are straight. Located onopposing arms are counter weights 50. The counter weights are, attachedto the arms and can be positioned along the arms to compensate foruneven weight distribution.

In operation, the arms are operated to raise or lower the plates toprovide support for any shaped spine fin coil that is being wound ontothe reel. When the spine fin coil is to be removed, the arms areretracted and the coil is pulled off the end of the mandrel.

In reference to FIGS. 4A and 4B, a plate pin type and or bridge platelike configuration (51 and 52; 61 and 62) is added to a shaper in FIG. 3where the adjustable corners are disposed with comb-like teeth 53 or 63for guiding the spine fins for a controlled deformation. The comb-teeth52 may be configured by “bridge” or “pin” type approaches. Tubing can beformed, on the winder reel, and/or the shaper, by using “points” muchlike a conduit bender. The comb like teeth may be configured on both theinner side and the outer side of the conduit as shown in FIG. 4B.

The deformation process improves to make the double roll coils with anarray of guiding teeth on the inside, another array of guiding teeth onthe outside of the coil, or other combinations of controlled deformationsuch as on the inner coil or the outer coil only, and any combinationthe customer desires. The controlled deformation can be performed at anytime during the production process depending on what the customer wants,it can be partially done in the coil shaper or at the winder, it can bedone in part, at the spine fin machines, before it is even, put on thereels for transfer to the coil winders, the deformation can be performedat the D-reel station and/or at the process just before it is to go intothe winder processing.

The “‘bridged’ and or “pin type” process can run the entire length ofthe “rails” or conduits or other fixture used to form or shape the coilsto the desired shape. The bridges and or pins are used to offset thedistance from the tip end of the spine fins and the edge of the tubing,to use the edge of tubing as the bending point and not outside edge ofthe spine fin itself. And a coil, may be wound to shape or shaped fromanother shape, using this technique, from the inside out, and from theoutside in.

The material can be made of a “softer” type material than the tubingitself so as not to dent the outer surface of the tubing products andthis may help, minimize any problems. Pins may be any shape dependent onthe surface desired, they may be angled, round, short, long, pointed,brush-like. Deforming of the fins in a controlled manner is by reason tomake a more efficient position for the fins that are behind tubing forair flow.

In order to bend tubing in coiling, the points approximately where thebend is located and used all along the length of the coil, for eachdesire bend.

Any and all types of surfaces can use this Controlled DeformationTechnique, it may help in the manufacturing process, because bydeforming the inside fins are better positioned in the flow of airposition, this will open up the inside radius of the coil for more room,for other equipment, such as compressors, and other coils etc. TheControlled Deformation can be performed at any place during themanufacturing process, from the point the spine fin is wrapped onto thetubing, or storage reels to the point at when the spine fin comes offthe reel, or before it goes on the winder or after the coil is on thewinder and or throughout the shaping process.

As shown in FIGS. 5A and 5B, the “fins” are generally delicate and areeasily deformed. A skilled person in the art may define approximatelywhere the controlled deformation is needed (as shown by example 70 and80), and as the spine fin 73 and tubing 74 (or 83) moves by in themanufacturing process, it may be channeled through a guide and a pintype apparatus, configured either like two wheels 71 and 72 on twosides, or like wheels 81 and 82 on the same side with reversed brushes,or a V-shaped tool or an array of other Deformation tools may be used toachieve the desired formation, an or placement of the fins as they areredirected to approximately, a more desirable “in the flow of air”position. Not behind the “tubing”.

None of the description in the present application should be read asimplying that any particular element, step, or function is an essentialelement which must be included in the claim scope: THE SCOPE OF PATENTEDSUBJECT MATTER IS DEFINED ONLY BY THE ALLOWED CLAIMS. Moreover, none ofthese claims are intended to invoke paragraph six of 35 USC section 112unless the exact words “means for” are followed by a participle.

The claims as filed are intended to be as comprehensive as possible, andNO subject matter is intentionally relinquished, dedicated, orabandoned.

What is claimed is:
 1. A method for a controlled deformation of a spinefin coil, comprises the steps of: placing in a conduit a straight tubehelically wrapped with a spine fin strip with plurality of spine fins;configuring said conduit with an array of comb-like guiding teeth,angled to prepare said plurality of spine fins for a controlleddeformation for a bend; connecting an end of the straight tube helicallywrapped with the spine fin strip to a reel or shaper; and rotating thereel or shaper to make a coil, wherein said reel includes variablelength arms and plates coupled to the variable length arms to make around bend for receiving a partially completed coil.
 2. The method claim1, wherein said conduit is configured at a bending corner of said reelor shaper.
 3. The method claim 1, wherein said conduit is configured tobe fully along said reel or shaper's perimeter.
 4. The method claim 1,wherein said comb-like guiding teeth are configured on both walls ofsaid conduit facing an inner side and an outer side of said coil.
 5. Themethod claim 1, wherein said comb-like guiding teeth are reversedbrushes, or a V-shaped tool.
 6. The method claim 1, wherein saidcomb-like guiding teeth are bridges or pins.
 7. A device system for acontrolled deformation of a spine fin coil, comprises: a conduit forguiding a straight tube helically wrapped with a spine fin strip withplurality of spine fins, wherein said conduit is configured with anarray of comb-like guiding teeth, angled to prepare said plurality ofspine fins for a controlled deformation for a bend; and A reel orshaper, mounted for making a coil, wherein said reel includes variablelength arms and plates coupled to the variable length arms to make around bend for receiving a partially completed coil.
 8. The devicesystem of claim 7, wherein said conduit is configured at a bendingcorner of said reel or shaper.
 9. The device system of claim 7, whereinsaid conduit is configured to be fully along said reel or shaper'sperimeter.
 10. The device system of claim 7, wherein said comb-likeguiding teeth are configured on both walls of said conduit facing aninner side and an outer side of said coil.
 11. The device system ofclaim 7, wherein said comb-like guiding teeth are reversed brushes, or aV-shaped tool.
 12. The device system of claim 7, wherein said comb-likeguiding teeth are bridges or pins.
 13. The device system of claim 7,wherein said conduit is configured at a crushing machine said beforestraight tube helically wrapped with a spine fin strip entering a winderreel.